Electrosurgical electrode having a non-conductive porous ceramic coating

ABSTRACT

An electrosurgical electrode assembly and method utilizing the same are disclosed capable of controlling or limiting the current per arc in real-time during an electrosurgical procedure. The conductive electrosurgical electrode is configured for being connected to an electrosurgical generator system and has a non-conductive, porous ceramic coating that “pinches” or splits the arc current generated by the electrosurgical generator system into the smaller diameter pores of the coating, effectively keeping the same current and voltage, but creating several smaller diameter arcs from one larger diameter arc. This has the effect of separating the arc current, effectively increasing the current frequency, resulting in a finer cut or other surgical effect. That is, the non-conductive, porous ceramic coating enables a low frequency current to achieve surgical results indicative of a high frequency current, while minimizing or preventing thermal damage to adjacent tissue.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. application Ser. No.10/728,211, now U.S. Pat. No. 7,033,354, filed on Dec. 4, 2003 by DavidS. Keppel entitled “ELECTROSURGICAL ELECTRODE HAVING A NON-CONDUCTIVEPOROUS CERAMIC COATING,” which claims priority from U.S. ProvisionalApplication No. 60/432,385 filed on Dec. 10, 2002 by David S. Keppelentitled “ELECTROSURGICAL ELECTRODE HAVING A NON-CONDUCTIVE POROUSCERAMIC COATING,” the entire contents of which are hereby incorporatedby reference herein.

BACKGROUND

1. Technical Field

The present disclosure is directed to electrosurgery and, in particular,to an electrosurgical electrode having a non-conductive porous ceramiccoating for controlling the amount of current per arc.

2. Description of the Related Art

Tissue heating is proportional to the square of the amount of currentbeing generated through the tissue and tissue vaporization is, in turn,generally proportional to current. Vaporization of tissue isproportional to the amount of energy in an arc. This energy, incombination with the Cathode Fall Voltage, derives the power forvaporization. Thermal spread is dependent on the amount of heatgenerated within the tissue and is dependent on tissue resistivity andthe arc energy squared. As can be appreciated, by not controlling thethermal spread the depth of ablation is difficult to predict andcontrol.

Therefore, during electrosurgery, an increase or decrease in the amountof current provides a different tissue effect. This phenomenon is due toa variable referred to as the crest factor (CF). The crest factor can becalculated using the formula: CF=V_(PEAK)/V_(RMS), where V_(PEAK) is thepositive peak of the waveform and V_(RMS) is the RMS value of thewaveform. The crest factor can also be calculated using the formula:CF=[(1−D)/D]^(1/2), where D is the duty cycle of the waveform and isdefined as D=T₁/(T₁+T₂).

Based on the above formulas, it is evident that when operating anelectrosurgical generator system in either the “cut”, “blend” or“coagulate” mode, the range of the crest factor varies from one mode toanother. For example, the “cutting” mode typically entails generating anuninterrupted sinusoidal waveform in the frequency range of 100 kHz to 4MHz with a crest factor in the range of 1.4 to 2.0. The “blend” modetypically entails generating an uninterrupted cut waveform with a dutycycle in the range of 25% to 75% and a crest factor in the range of 2.0to 5.0. The “coagulate” mode typically entails generating anuninterrupted waveform with a duty cycle of approximately 10% or lessand a crest factor in the range of 5.0 to 12.0. For the purposes herein,“coagulation” is defined as a process of desiccating tissue wherein thetissue cells are ruptured and dried. “Vessel sealing” is defined as theprocess of liquefying the collagen in the tissue so that it reforms intoa fused mass with significantly-reduced demarcation between the opposingtissue structures (opposing walls of the lumen). Coagulation of smallvessels is usually sufficient to permanently close them. Larger vesselsneed to be sealed to assure permanent closure.

An increase in the crest factor results in more current per arc at agiven power setting. Further, since tissue heating is proportional tothe amount of current through the tissue squared and tissue vaporizationis proportional to the amount of current being generated through thetissue, a doubling of current per arc results in four times as muchtissue heating and twice the amount of tissue vaporization when anelectrode connected to the electrosurgical generator system contacts thetissue. Known electrodes cannot control or limit the current per arc toachieve a particular surgical effect, e.g., a fine cut. Accordingly,such electrodes do not have the ability to manipulate or control theproportion of tissue vaporization to tissue heating, in order to achievemore controllable and desirable surgical effects.

Therefore, it is an aspect of the present disclosure to provide anelectrosurgical electrode capable of controlling or limiting the currentper arc for controlling the both tissue heating and tissue vaporization.

SUMMARY

An electrosurgical electrode and electrosurgical generator systemcapable of controlling or limiting the current per arc in real-timeduring an electrosurgical procedure is disclosed. The conductiveelectrosurgical electrode is configured for being connected to anelectrosurgical generator system and has a non-conductive, porousceramic coating that “pinches” or splits the arc current generated bythe electrosurgical generator system into a small diameter channel,effectively keeping the same current and voltage, but creating severalsmall arcs from one large arc.

This has the effect of separating the arc current, effectivelyincreasing the current frequency, resulting in a finer cut or othersurgical effect. That is, the non-conductive, porous ceramic coatingenables the application of a low frequency current to achieve surgicalresults indicative of a high frequency current, while minimizing orpreventing thermal damage to adjacent tissue.

The number of small arcs created from one large arc is inverselyproportional to the diameter of the pores in the ceramic coating.Preferably, the diameter of each pore is less than the diameter of thearc. Hence, when electrosurgical current is applied to theelectrosurgical electrode, the arc current is split between the pores inthe electrode, thereby, controlling or limiting the arc current througheach pore. This effect which controls or limits the arc current througheach pore is referred to as MicroHollow Cathode Discharge (MCD or MHCD).

The diameter of each pore can vary from the diameter of other pores toproduce different surgical effects when operating the electrosurgicalgenerator system in one of several modes, such as cut, blend andcoagulation modes. In either embodiment, MCD enables the surgeon tocontrol the proportion of tissue vaporization to tissue heating, inorder to achieve more controllable and desirable surgical effects.

The number of pores per square centimeter controls the arc area. As thenumber of pores per square centimeter increases, the arc area decreases,and vice versa. A large arc area is desired when operating theelectrosurgical generator system in the coagulation mode and a small arcarea is desired when operating in the cut mode. The thickness of thenon-conductive, porous ceramic coating controls the system resistanceand voltage needed to establish the arc. The thicker the coating thegreater the system resistance and voltage needed to establish the arc,and vice versa.

Alternative embodiments provide for the non-conductive, porous ceramiccoating to be applied to roller-ball type electrodes for improving thearc distribution across the tissue, and hence, the efficiency of theelectrode, as compared to roller-ball type electrodes not coated withthe non-conductive, porous ceramic material. Other embodiments andfeatures include modifying the geometry of the electrode before applyingthe non-conductive, porous ceramic coating on the electrode, so as tocontrol where the arc is split and/or cutting/coagulating occurs, i.e.,along edge of the electrode, along length of the electrode, across widthof the electrode, etc.

Further, the electrode can be coated accordingly to provide an electrodehaving at least a portion thereof configured for cutting tissue, atleast a portion thereof configured for coagulating tissue, etc. Furtherstill, the pore diameter, the pore length, and/or pore pattern can bevaried to produce different effect to control cutting and coagulatingtissue.

According to one embodiment of the present disclosure an electrodeassembly for controlling the electrosurgical arc current from anelectrosurgical generator is disclosed. The electrode assembly includesan electrode having a conductive surface adapted to connect to a sourceof electrosurgical energy, said electrode having a width and a length.The electrode assembly also includes a non-conductive, porous ceramicmaterial substantially coating said conductive electrode. Thenon-conductive, porous ceramic material has a predetermined thicknessand includes a plurality of pores dispersed therein having a diameterand a depth. The non-conductive, porous ceramic material varies inthickness across the length and width of the electrode. Furthermore, thediameter and the depth of the pores of the non-conductive, porousceramic material vary across the length and width of the electrode. Uponactuation of the electrosurgical generator, electrosurgical energy fromthe electrosurgical generator creates an initial arc current across theconductive surface of the electrode. The initial arc current has adiameter greater than the diameter of the pore such that the initial arccurrent is forced to split into a plurality of subsequent arc currentshaving a diameter smaller than the diameter of the initial arc currentin order to conduct electrosurgical energy through the pores of thenon-conductive, porous ceramic material.

According to another embodiment of the present disclosure a method forcontrolling the amount of electrosurgical energy to tissue is disclosed.The method includes the step of providing an electrode having aconductive surface adapted to connect to a source of electrosurgicalenergy, said electrode having a predetermined width and a length. Themethod also includes the step of coating the electrode with anon-conductive, porous ceramic material having a thickness and aplurality of pores dispersed therein each having a diameter and a depth.The non-conductive, porous ceramic material varies in thickness acrossat least one of the length and width of the electrode. Furthermore, thediameter and the depth of said pores of said non-conductive, porousceramic material vary across at least one of a length and a width of theelectrode. The method further includes the step of activating theelectrosurgical energy source to create an initial arc current acrossthe conductive surface of the electrode. The initial arc has a diametergreater than the diameter of said pores such that the initial arccurrent is forced to split into a plurality of subsequent arc currentshaving a smaller diameter than the diameter of the initial arc currentin order to conduct electrosurgical energy through the pores of thenon-conductive, porous ceramic coating.

According to a further embodiment of the present disclosure an electrodeassembly for controlling the electrosurgical arc current from anelectrosurgical generator is disclosed. The electrode assembly includesan electrode having a conductive surface adapted to connect to a sourceof electrosurgical energy. The electrode has a modified geometry adaptedfor controlling splitting of the electrosurgical arc. The electrodeassembly further includes a non-conductive, porous ceramic materialsubstantially coating said conductive electrode, said non-conductive,porous ceramic material has a predetermined thickness and includes aplurality of pores dispersed therein having a diameter and a depth. Thediameter of said pores of said non-conductive, porous ceramic materialvaries across the modified geometry. Upon actuation of theelectrosurgical generator, electrosurgical energy from theelectrosurgical generator creates an initial arc current across theconductive surface of the electrode. The initial arc current has adiameter greater than the diameter of the pore such that the initial arccurrent is forced to split into a plurality of subsequent arc currentshaving a diameter smaller than the diameter of the initial arc currentin order to conduct electrosurgical energy through the pores of thenon-conductive, porous ceramic material.

Further features of the above embodiments will become more readilyapparent to those skilled in the art from the following detaileddescription of the apparatus taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

Various embodiments will be described herein below with reference to thedrawings wherein:

FIG. 1 is an enlarged, cross-sectional view of a portion of a conductiveelectrode coated with a non-conductive, porous ceramic coating inaccordance with the present disclosure;

FIG. 2 is an enlarged, cross-sectional view of a conductive electrodecoated with a non-conductive, porous ceramic coating having varying porediameters, varying pore lengths, and varying number of pores per squarecentimeter in accordance with the present disclosure;

FIG. 3 is an enlarged, cross-sectional view of a conductive electrodecoated with a non-conductive, porous ceramic coating with variousthicknesses in accordance with the present disclosure;

FIG. 4 is an enlarged, cross-sectional view of a roller-ball type,conductive electrode coated with a non-conductive, porous ceramiccoating in accordance with the present disclosure;

FIG. 5 is an enlarged, cross-sectional view of a conductive electrodehaving a modified geometry and coated with a non-conductive, porousceramic coating in accordance with the present disclosure; and

FIG. 6 is an enlarged, cross sectional view of a forceps having twoopposing jaw members coated with a non-conductive, porous ceramiccoating in according with the present disclosure.

DETAILED DESCRIPTION

Reference should be made to the drawings where like reference numeralsrefer to similar elements. Referring to FIG. 1, there is shown anenlarged, cross-sectional view of one embodiment of a conductiveelectrode according to the present disclosure. The electrode isdesignated generally by reference numeral 100 and it is connected to anelectrosurgical generator system 102. The electrode 100 is coated with anon-conductive, porous ceramic coating 104 which “pinches” or splits thearc current generated by the electrosurgical generator system 102 into asmall diameter channel, effectively keeping the same current andvoltage, but creating several small arcs from one large arc.

This has the effect of separating the arc current, effectivelyincreasing the current effect to the tissue, resulting in a finer cut orother surgical effect. That is, the non-conductive, porous ceramiccoating 104 enables a low frequency current to achieve surgical resultsindicative of a high frequency current, while minimizing or preventingthermal damage to adjacent tissue.

The coating 104 includes a plurality of pores 106 having a uniformdiameter “D” in the range of 10 μm to 1000 μm and a uniform length “L”(100 to 500 micrometers). The number of small arcs created from onelarge arc is inversely proportional to the diameter “D” of the pores 106in the ceramic coating 104. Preferably, the diameter “D” of each pore106 is less than the diameter of the arc. Hence, when electrosurgicalcurrent is applied to the electrosurgical electrode 100, the arc currentis split between the pores 106 in the electrode 100, thereby,controlling or limiting the arc current through each pore 106. Thiseffect which controls or limits the arc current through each pore 106 isreferred to as “MicroHollow Cathode Discharge” (MCD or MHCD).

As shown by FIG. 2, it is envisioned that the diameter “D” and thelength “L” of the plurality of pores 106 can vary in size to producedifferent surgical effects when operating the electrosurgical generatorsystem 102 in one of several modes, such as cut, blend and coagulationmodes. In either embodiment, MCD enables the surgeon to control theproportion of tissue vaporization to tissue heating, in order to achievemore controllable and desirable surgical effects.

Additionally, as shown by FIG. 2, the number of pores per squarecentimeter (or the pattern of the pores 106) can be uniform (as shown byFIG. 1) or vary along the length of the electrode 100. The number ofpores per square centimeter controls the arc area. As the number ofpores per square centimeter increases, the arc area decreases, and viceversa. A large arc area is desired when operating the electrosurgicalgenerator system 102 in the coagulation mode and a small arc area isdesired when operating in the cut mode.

The thickness of the non-conductive, porous ceramic coating 104 controlsthe system resistance and voltage needed to establish the arc. Thethicker the coating 104 the greater the system resistance and voltageneeded to establish the arc, and vice versa. With continued reference toFIG. 1, the coating 104 has a thickness “T” which is predeterminedduring fabrication of the electrode 100 for effectively operating theelectrode 100 in one of several modes, such as cut, coagulate and blend,by using the electrosurgical generator system 102. A small thickness forthe coating 104 in the range of 10 μm to 500 μm is preferred foroperating the electrode 100 in the “cut” mode; a medium thickness in therange of 250 μm to 1 mm is preferred for operating the electrode 100 inthe “blend” mode; and a large thickness in the range of 500 μm to 2 mmis preferred for operating the electrode 100 in the “coagulate” mode.

As shown by FIG. 3, the thickness “T” of the coating 104 can vary at oneportion 108 of the electrode 300 with another portion 110 of theelectrode 300, in order to be able to effectively operate the electrode300 in more than one mode by using the electrosurgical generator system102. The electrode 300 shown by FIG. 3 has two portions 108 a, 108 b foreffectively operating the electrode 300 in the coagulate mode, and oneportion 110 for effectively operating the electrode 300 in the cut mode.

It is envisioned that the two opposing jaw members may be created withcoating 104 in this manner to simultaneously effect tissue sealingbetween two opposing 108 a portions and 108 b portions of each jawmember and effect tissue cutting between two opposing 110 portions. Moreparticularly, the thicker coating areas 108 a and 108 b on each jawmember will tend to coagulate tissue held there between while the thincoating area 110 will tend to cut tissue held therebetween. As can beappreciated, it is envisioned that a single energy activation may yielda dual tissue effect which greatly simplifies sealing and dividingtissue.

With reference to FIG. 4, there is shown an enlarged, cross-sectionalview of a roller-ball type electrode 400 coated with the non-conductive,porous ceramic coating 104 in accordance with the present disclosure.The coating 104 for this type of electrode improves the arc distributionacross the tissue, and hence, the efficiency of the electrode 400, ascompared to roller-ball type electrodes not coated with thenon-conductive, porous ceramic material.

With reference to FIG. 5, there is shown an enlarged, cross-sectionalview of an electrode 500 having a modified geometry and coated with thenon-conductive, porous ceramic coating 104 in accordance with thepresent disclosure. The geometrical configuration of the electrode 500enables control of where the arc is split and/or cutting/coagulatingoccurs, e.g., along edge of the electrode 500, along the length ofelectrode 500, across the width of electrode 500, etc. Variousdiameters, lengths, and patterns (number of pores per square centimeter)for the pores 106 are contemplated besides uniform diameter, length anduniform distribution. Also, a varying or uniform thickness for thecoating 104 is contemplated.

The method of the present disclosure includes the steps of providing anelectrode having a conductive surface connected to a source ofelectrosurgical energy, and coating the electrode with a non-conductive,porous ceramic material having a thickness and a plurality of poresdispersed therein each having a diameter. The method further includesthe step of activating the electrosurgical energy source to create aninitial arc current across the conductive surface of the electrode. Theinitial arc has a diameter greater than the diameter of the pores suchthat the initial arc current is forced to split into a plurality ofsubsequent arc currents having a smaller elevator than the diameter ofthe initial arc current in order to conduct electrosurgical energythrough the pores of the non-conductive, porous ceramic coating.

From the foregoing and with reference to the various figure drawings,those skilled in the art will appreciate that certain modifications canalso be made to the present disclosure without departing from the scopeof the same. For example, it is envisioned that the pore diameter of thecoating 104 may be varied during the manufacturing process according tothe type of instrument being used. For example, one size pore diametermay be used for electrosurgical blades for coagulating or cutting tissuewhich another pore diameter may be used for electrosurgical forcepswhich utilized a combination of closing force, gap distance between jawmembers and electrosurgical energy, to seal tissue. Moreover, it isenvisioned that the number of pores per inch may be modified during themanufacturing process to control the arc area and adverse collateraleffect to surrounding tissue. It is also contemplated that the thicknessof the coating may be modified during manufacturing to establish apreferred resistance and voltage for creating the arc.

Although this disclosure has been described with respect to preferredembodiments, it will be readily apparent to those having ordinary skillin the art to which it appertains that changes and modifications may bemade thereto without departing from the spirit or scope of thedisclosure.

1. An electrode assembly for controlling the electrosurgical arc currentfrom an electrosurgical generator, the electrode assembly comprising: anelectrode having a conductive surface adapted to connect to a source ofelectrosurgical energy, said electrode including a width and a length; anon-conductive, porous ceramic material substantially coating saidconductive electrode, said non-conductive, porous ceramic materialhaving a thickness and including a plurality of pores dispersed thereinhaving a diameter and a depth, said non-conductive, porous ceramicmaterial varying in thickness across at least one of the length andwidth of the electrode, wherein the diameter and the depth of said poresof said non-conductive, porous ceramic material vary across at least oneof a length and a width of the electrode; and wherein upon actuation ofthe electrosurgical generator, electrosurgical energy from theelectrosurgical generator creates an initial arc current across theconductive surface of the electrode, the initial arc current having adiameter greater than the diameter of the pore such that the initial arccurrent is forced to split into a plurality of subsequent arc currentshaving a diameter smaller than the diameter of the initial arc currentin order to conduct electrosurgical energy through the pores of thenon-conductive, porous ceramic material.
 2. An electrode assemblyaccording to claim 1, wherein the number of pores per inch varies acrossat least one of a length and a width of the electrode.
 3. An electrodeassembly according to claim 1, wherein the diameter of said pores ofsaid non-conductive, porous ceramic coating is within a range of about10 to about 1000 micrometers.
 4. An electrode assembly according toclaim 1, wherein the depth of said pores of said non-conductive, porousceramic coating is within a range of about 100 to about 500 micrometers.5. An electrode assembly according to claim 1, wherein thenon-conductive, porous ceramic material is dispersed on a pair ofopposing jaw members of a forceps.
 6. An electrode assembly according toclaim 5, wherein the thickness of the non-conductive, ceramic materialvaries across a length of each of the opposing jaw members.
 7. Anelectrode assembly according to claim 6, wherein the non-conductive,ceramic material on each of the jaw members includes a first thicknessdispersed near a distal and a proximal end of each jaw member and asecond thickness dispersed between the proximal and distal ends of eachjaw member, said first thickness being dimensioned to effectively sealtissues disposed between the opposing jaw members upon electrosurgicalactivation and said second thickness being dimensioned to effectivelycut tissue dispersed between the opposing jaw members uponelectrosurgical activation.
 8. An electrode assembly according to claim1, wherein the electrode is at least one of a roller ball electrode anda blade electrode.
 9. A method for controlling the amount ofelectrosurgical energy to tissue comprising the steps of: providing anelectrode having a conductive surface adapted to connect to a source ofelectrosurgical energy, said electrode including a width and a length;coating said electrode with a non-conductive, porous ceramic materialhaving a thickness and a plurality of pores dispersed therein eachhaving a diameter and a depth, said non-conductive, porous ceramicmaterial varying in thickness across at least one of the length andwidth of the electrode, wherein the diameter and the depth of said poresof said non-conductive, porous ceramic material vary across at least oneof a length and a width of the electrode; and activating theelectrosurgical energy source to create an initial arc current acrossthe conductive surface of the electrode, said initial arc having adiameter greater than the diameter of said pores such that the initialarc current is forced to split into a plurality of subsequent arccurrents having a smaller diameter than the diameter of the initial arccurrent in order to conduct electrosurgical energy through the pores ofthe non-conductive, porous ceramic coating.
 10. An electrode assemblyaccording to claim 9, wherein the diameter of said pores of saidnon-conductive, porous ceramic coating is within a range of about 10 toabout 1000 micrometers.
 11. An electrode assembly according to claim 9,wherein the depth of said pores of said non-conductive, porous ceramiccoating is within a range of about 100 to about 500 micrometers.
 12. Anelectrode assembly for controlling the electrosurgical arc current froman electrosurgical generator, the electrode assembly comprising: anelectrode having a conductive surface adapted to connect to a source ofelectrosurgical energy, said electrode having a modified geometryadapted for controlling splitting of the electrosurgical arc; anon-conductive, porous ceramic material substantially coating saidconductive electrode, said non-conductive, porous ceramic materialhaving a thickness and including a plurality of pores dispersed thereinhaving a diameter and a depth wherein the diameter of said pores of saidnon-conductive, porous ceramic material varies across the modifiedgeometry; and wherein upon actuation of the electrosurgical generator,electrosurgical energy from the electrosurgical generator creates aninitial arc current across the conductive surface of the electrode, theinitial arc current having a diameter greater than the diameter of thepore such that the initial arc current is forced to split into aplurality of subsequent arc currents having a diameter smaller than thediameter of the initial arc current in order to conduct electrosurgicalenergy through the pores of the non-conductive, porous ceramic material.13. An electrode assembly according to claim 12, wherein the number ofpores per inch varies across at least one of a length and a width of theelectrode.
 14. An electrode assembly according to claim 12, wherein thediameter of said pores of said non-conductive, porous ceramic coating iswithin a range of about 10 to about 1000 micrometers.
 15. An electrodeassembly according to claim 12, wherein the depth of said pores of saidnon-conductive, porous ceramic coating is within a range of about 100 toabout 500 micrometers.
 16. An electrode assembly according to claim 12,wherein the non-conductive, porous ceramic material is dispersed on apair of opposing jaw members of a forceps.
 17. An electrode assemblyaccording to claim 16, wherein the thickness of the non-conductive,ceramic material varies across the modified geometry of each of theopposing jaw members.
 18. An electrode assembly according to claim 17,wherein the non-conductive, ceramic material on each of the jaw membersincludes a first thickness dispersed near a distal and a proximal end ofeach jaw member and a second thickness dispersed between the proximaland distal ends of each jaw member, said first thickness beingdimensioned to effectively seal tissues disposed between the opposingjaw members upon electrosurgical activation and said second thicknessbeing dimensioned to effectively cut tissue dispersed between theopposing jaw members upon electrosurgical activation.